First bike, first project

[meelas]

First Day of Work

Hey everyone! Here is a 1980 xs400 that i bought recently. It has 6,300+ original miles. After some early battery charging issues, I have been able to start working on it and hopefully will get it running smoothly and registered before the snow starts to fall.

I want to make this thread so I can record the progress and ask for help if I need it along the way.

The handle bars and white tank were done by the previous owner. It is actually just a primer. The p.o. was working on the bike but then sold it after buying a car instead.

I started by adding an inline fuel filter. Then i took off the stock air filters and found a whole mess of wires and the battery sitting on an old rusted first aid kit cover. The oil drain plug was stripped, so I replaced that. The spark plugs were also replaced.

 

[drewpy]

good start, keep up the work

 

[meelas]

Second Day of Work

There is a photo of the battery bracket/holder. Also there is a strap that I use to wrap the battery secure. I removed the rear tail/handle. Used adjustable L-brackets to remount the license plate light. I need to figure out what to do about the rear blinker that is falling off.
New air filters arrived in the mail. Emgo filters. That's it for now, I guess.

Mac 2 into 2 exhaust is on the way, hopefully I can install them on Friday.

 

[meelas]

Third Day of Work

I ordered Mac Performance 2 into 2 exhaust pipes and I just replaced the rusted stock ones. It definitely sounds really nice, and the backfiring and rattling has all but disappeared. Now I need to figure out how to rejet the carbs.

 

[speedfoos]

Nice! Your recent '80 XS400 is in much better shape than mine. Good luck on getting ready to go.

 

[Lou Ranger]

... I need to figure out what to do about the rear blinker that is falling off ...

There is positively an epidemic of drewpy blinkers all of a sudden!

Your bike looks wonderful. With it having so little mileage, you will have plenty of tread, but make sure you check the date codes moulded into each tire. You wouldn't want to venture into that pink zone on your speedometer on a 32 year old tire.

 

[drewpy]

a drewpy indicator clearly means it isn't performing as it should!

 

[meelas]

sorry for the long hiatus. i have been working as much/often as I can, I just havent really been posting all the progress because I have been spending my free time actually riding the bike, haha.

Day 4. First attempt to rejet the carbs. First rebuilt them with new gaskets, needles, and jets. Took them on and off about 7 or 8 times. 142.5 was too big. Stuck to 135 main jet, with 2 full turns of the mixture screws. Adjusted idle screw as needed.

Day 5. Rode around the parking lot, sounds good. Still has some problem starting up right away. Needs some time to warm up. Smoke coming from carbs. Removed in-line fuel filter (too big), and replaced original fuel hose for a smaller one. No more leaking.

Day 6. Brought bike to get registered. Success! Rode home, no problems, except high idle when clutch engaged/in neutral.

Day 7. Started to clean rust off of fenders. Deciding to put them back on to see how they look. Used metal brush, WD-40. Took off shocks to clean. Unsuccessfully tried to figure out why electric starter isn't working.

Day 8. Adjusted mixture screw to 3. Started to pop. Readjusted the screw to 2.5 turns. Runs much better, but idle is still slightly sticking.

 

[meelas]

Day 9. Took off carbs, installed new throttle cable, cleaned with WD-40 and metal brush. Fixed throttle sticking problem. Added screw to act as a locking pin for the front wheel. Need to replace with a proper lock asap.

Day 10. Played around with the idle screw a little more, and the high idle magically disappeared. Replaced broken throttle sleeve with new one. Mounted rear fender, relocated lights and license plate (currently very sketchy). Cleaned up mufflers with metal brush.

Day 11. Changed brake fluid, now front brakes actually work properly. Straightened headlight bracket, front blinkers, and cleaned inside. Loosened clutch a little bit.

Day 12. Lightly sanded various metal parts (headlight, tail light, rear bar. Adjusted headlight direction. Need new bulbs for instrument panel. A12v3.4w bulb... where can I find this?

Day 13. Rear light bracket arrived, so I installed that and straightened out the license plate holder.

To Do: 1. Figure out electric start problem. I'm thinking it's the solenoid at this point.
2. Paint (cant decide whether or not to keep it white, at the moment)
3. Reupholster seat/Fix up edges where its ripped
4. Maybe i'll get the kick stand welded back on... not sure if i really need it.
5. Make small bags to replace where side covers originally go.
6. And also fix that silly turn signal that is still drooping

 

[meelas]

So.... I haven't updated this in over two years. I have been lurking and coming back to read up on any issues, but I realized I should also contribute to the community that has helped me out so much with my bike.

At one point, I almost ended up selling the bike, but I just couldn't get myself to do it. I did buy a second bike, (1977 KZ650, but while I still work on that, my xs400 is my daily driver.)

If you have any questions of what I have done, please feel free to ask. It will always be a work in progress. With limited funds, it is still a rough bike, but I love it.

edit: sorry for all the different types of photos, they were all taken over the course of the last year or so

 

[levdir]

Looks good! I dig the Suprematist tank graphics.

 

[meelas]

Haha, i was taping some wires up and ended up with some extra pieces. it just happened and i liked it

 

[Sesty]

looks good, did u shorten the front fender

 

[meelas]

Nah, I didn't shorten the front fender. It's stock, just plasti-dipped it

 

[xschris]

Welcome back Most people join to fix an issue then are gone. It's good to see some old faces.

 

[meelas]

Thanks Chris. I am pretty sure I bought some parts from you, so, thanks!

 

[xschris]

I have sold a lot of stuff to people on here over the years. It's very possible

 

[JaredK]

Looks great! Love the new seat and the side bag. The new bars seem to suit the bike better, too.